Rotating Angled Caulking Nozzle

ABSTRACT

Angled caulking nozzles allow for the optimal application of sealant materials in hard-to-reach areas. Provided herein are novel devices, methods, and designs for angled caulking nozzles which incorporate handles or other protrusions. The handles or other protrusions allow for the facile rotation of the angled caulking nozzle such that the angled dispensing tip may be easily and optimally positioned.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based on and claims the benefit of priority of U.S.Provisional Patent Application Ser. No. 61/555,041, filed on Nov. 3,2011, the contents of which are incorporated by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTINGCOMPACT DISK APPENDIX

Not Applicable.

FIELD OF THE INVENTION

The invention relates to the fields of construction, plumbing, andrelated arts. The inventions described herein comprise novel tools forthe application of caulk, sealant material, and other materials extrudedfrom caulking guns or similar devices.

BACKGROUND AND SUMMARY OF THE INVENTION

Adhesive and sealing materials such as caulk and silicone are applied incountless situations in construction, plumbing, finishing, and homerepair. These materials are routinely supplied in tubes and appliedusing a caulking gun which extrudes the material from a nozzle at theend of the tube. Commercially available tubes have integrated nozzleswhich are oriented along the long axis of the tube and caulking gunbarrel. Such straight nozzles are perfectly suited to most jobs.However, in myriad situations the materials need to be applied inconfined spaces, irregular spaces, and other difficult-to-reach areas.In such case it would be advantageous to have a system that allowed forthe application of the material at an angle deviating from the long axisof the tube and caulking gun barrel. Provided herein are devices,methods, and systems which fulfill this unmet need.

The invention is directed to the application of materials using acaulking gun. Such materials are typically supplied in cartridges, or“tubes,” which consist of an oblong cylinder. At one end, the cylinderis plugged with a disk shaped plug that is capable of moving within thebody of the cylinder when pressure is applied to it. The other end ofthe tube is sealed with a non-moveable end wall. In the center of thiswall is a small hole with a nozzle protruding from it, as describedbelow. In the United States, such tubes are typically sold in two sizes,10 fluid ounce tubes, and 28 fluid ounce tubes. The invention isdirected to any size or shape tube compatible with caulking guns. Forconvenience, such tubes will be referred to as “sealant tubes.”

The nozzle, or “caulking tip,” protruding from the sealant tube istypically cone-shaped or consists of a short, substantially cylindricalbody topped with a conical end. The tapering of the cone-shaped end ofthe nozzle allows the user to cut the nozzle at a range of diameters sothat the bead of sealant material extruded from the tube will be of thedesired diameter for the application. Commercially available sealanttubes have an integrated nozzle which is oriented parallel to the longaxis of the sealant tube. For reference, “straight” nozzles will referto such integrated sealant tube nozzles which are parallel to the longaxis of the sealant tube.

Sealant tubes are capable of being loaded into appropriately sizedcaulking guns. The caulking gun is a device with a moveable piston orplunger having the same diameter as the inner diameter of the sealanttube. By squeezing a trigger, the user can ratchet the piston or plungerforward, putting pressure on the moveable plug at the distal end of thesealant tube and forcing material to flow from the nozzle. Anappropriately sized caulking gun will have a disk shaped plunger thatmatches the inner diameter of the sealant tube. The invention isdirected to the use of any caulking gun or apparatus, includinghand-powered and motorized designs, which utilizes a plunger or pistonto extrude materials from a sealant tube. Additionally, there arecaulking guns which do not utilize disposable sealant tubes. These bulkor “sausage” type guns extrude bulk materials or packets of materialfrom a solid cylindrical barrel. The invention is further directed tothe use of these bulk-type caulking guns.

Many types of materials are supplied in sealant tubes. Elastomericsealants, sometimes called “caulk,” are commonly supplied in thesetubes, for example, silicone, polyurethane, polysulfide, polyurethaneand acrylic sealants. Various adhesives, including constructionadhesives (commonly called “liquid nails”) are also supplied in suchtubes. The invention is directed to any material supplied in a caulkinggun-compatible sealant tube, or dispensed from a caulking gun, such as abulk-type caulking gun, and will, for convenience, be referred to as“sealant material.”

Sealant materials are often applied in difficult-to-reach areas orconfined spaces. In some situations, the standard integrated straightnozzle will not reach the desired area. In other situations, a standardstraight nozzle can access the desired area, but the body of thecaulking gun will block the user's line of sight to the applicationarea, which makes precise application difficult. In yet othersituations, the user must align his or her body or arm at anuncomfortable angle in order to access the application area. In suchsituations, it would be advantageous to have a nozzle which can bereadily positioned at an angle other than parallel to the long axis ofthe sealant tube and caulking gun barrel.

Various bent, or angled nozzles are known in the art. These nozzlespoint at angles deviating from the long axis of the caulking gun barrel,allowing the user to apply sealant material in difficult-to-reach spotsor affording the user a better view of the application zone, allowingfor more precise application of the sealant material. Some of theseprior art angled nozzles are intended to be integrated into a sealanttube. Others constitute a replacement tip that slides over a standard,integrated tip and which, when fit in place, act as an extension of thesealant tube's integrated nozzle, providing an angled tip.

Exemplary commercially available angled nozzles include the 360 ProCaulking Tip™ (TCIndustriesUSA) and the AngleShot™ (Albion Engineering).Additional prior art angled nozzles include those described in U.S.Design Pat. D377,891 by Benich, U.S. Design Pat. D468,601 by Horst, U.S.Design Pat. D476, 538 by Dorff, U.S. Design Pat. D598,722 by Coll, andU.S. Pat. No. 7,014,079 by Swann. Additional angled nozzles aredisclosed in U.S. Design Pat. D660,106, as well as in pending U.S.Design patent application Ser. No. 29/402,801, U.S. Design patentapplication Ser. No. 29/402,802, and U.S. Design patent application Ser.No. 29/402,805, by C. Cross, inventor of the present disclosure.

Although angled nozzles are known in the art, the Applicant hasdiscovered a novel modification of the angled nozzle which greatlyimproves the ease of use of an angled nozzle. The modification comprisesthe addition of one or more protrusions from the nozzle which allowquick, easy, and precise rotation of the angled nozzle so that it may beplaced in the optimal position for the user's current sealantapplication. These protrusions greatly increase the versatility and easeof use of angled nozzles.

DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts an exemplary winged angled nozzle of the invention.

FIG. 2 depicts an exploded view of an assembly comprising an exemplarywinged angled nozzle of the invention, a sealant tube, and a caulkinggun.

FIG. 3 depicts six exemplary embodiments of the winged nozzle concept,with the angled portion of the nozzle being angled towards the viewer.FIG. 3A depicts exemplary paddle-shaped wings. FIG. 3B depicts exemplaryrectangular wings. FIG. 3C depicts exemplary polygonal wings. FIG. 3Ddepicts exemplary polygonal wings. FIG. 3E depicts circular wings. FIG.3F depicts exemplary circular wings.

FIG. 4 depicts multiple views of an exemplary winged angled nozzle. FIG.4A depicts a side view of an exemplary winged angled nozzle. FIG. 4Bdepicts a perspective view of an exemplary winged angled nozzle. FIG. 4Cdepicts a top view of an exemplary winged angled nozzle. FIG. 4D depictsa frontal view of an exemplary winged angled nozzle. FIG. 3E depicts abottom view of an exemplary winged angled nozzle.

DETAILED DESCRIPTION OF THE INVENTION

The invention comprises an angled nozzle with one or more protrusionsfrom the nozzle which aid the user in rotating the nozzle to the desiredorientation. In some embodiments, the invention comprises twoprotrusions oriented 180 degrees from each other, somewhat visuallyreminiscent of wings. Accordingly, for ease of reference, theprotrusions that aid in rotation of the nozzle will hereafter bereferred to as “wings” and nozzles comprising such protrusions willhereafter be referred to as “winged” nozzles. However, it is understoodthat the protrusions which aid the user in rotating the nozzle maycomprise any number of configurations, including single protrusions,double protrusions, triple protrusions, and other multiple protrusions;protrusions of any shape and size, and protrusions of varyingorientations around the body of the nozzle.

The basic concept of the invention is exemplified in FIG. 1, whichdepicts one embodiment of the winged nozzle. The winged nozzle comprisesa hollow, tubular body, which will be referred to as the “body” (102).Continuous with the body is a an angled section (103) which angles awayfrom the long axis of the body and which terminates with a conical ortapered tip (104). It will be understood by one of skill in the art thatthe inner lumen of the nozzle initiates with an opening at the base ofthe body and is continuously hollow from the base of the body to thetip. This hollow interior allows (a) the insertion of an integratedstraight nozzle into the winged nozzle; and (b) allows the flow ofextruded material through the winged nozzle. At the base of the nozzle,the body is circumscribed by a substantially planar base (101).Protruding from the body is one or more handle or “wing” (105).

The winged nozzle is typically utilized in combination with a sealanttube and caulking gun, as illustrated in FIG. 2. The straight nozzle ofa standard sealant tube (205) is cut, at any point along its length, toallow the flow of sealant. The winged nozzle is placed over the straightnozzle of the standard sealant tube, with the base of the winged nozzle(201) sitting substantially flush against the front surface of thesealant tube (206), such that the sealant tube's nozzle (205) isenclosed within the hollow body portion (202) of the winged nozzle. Thesealant tube and winged nozzle are then fit into a caulking gun suchthat the base of the winged nozzle (201) is held fast between the end ofthe sealant tube (206) and the front end plate (209) of the caulkinggun. The body (202), angled portion (204), wings (203) and enclosednozzle of the sealant tube (205) protrude from the opening in the frontend plate of the caulking gun (208). By pushing, gripping, or otherwiseengaging the wing(s) (203) with his or her fingers, the user can quicklyand easily rotate the angled portion (204) of the winged nozzle into anoptimal position for the task at hand. At any time, e.g. before, during,or after placement of the winged nozzle over the standard sealant tubeand its placement in the caulking gun, the user can cut the angledportion of the nozzle (204) at any point along its length, to create anopening of the desired size. When the plunger or piston of the caulkinggun is engaged (210), sealant is then extruded through the straightnozzle of the sealant tube, into the winged nozzle, and then ischanneled out the angled tip portion of the device.

The winged nozzles of the invention may be configured in myriaddifferent ways. The base (101), encircles the basal end of the body andacts as a shelf or flange, radiating perpendicularly from the basal endof the body. The base can be of any shape or size, so long as it fitswithin the barrel of the caulking gun. Additionally, the base must beadequately wide such that it does not fall out of the front end plateopening (208) of the caulking gun. The base may comprise a continuousshelf or flange, or may comprise a series of discontinuous multipleprotrusions radiating perpendicularly from the basal end of the body. Apreferred configuration for the base is a circular or substantiallycircular flange having a diameter substantially equal to the diameter ofthe sealant tube. For example a circular base with a diameter of about 1and 13/16^(th) inches may be used for a standard 10 fluid ounce caulkingtube. Preferably the base is flat or substantially flat such that itsits flush against the front surface (206) of the sealant tube andprevents significant backflow of sealant material out of the base of thebody (202).

The body may be of any shape. In some embodiments, the body issubstantially cylindrical (i.e. circular). The size of the body mayvary, but its inner lumen cross-sectional area must be adequately largethat the sealant tube's straight nozzle will fit within it. The outerdiameter of the body base must be adequately small that it will fitthrough the opening (208) in the dispensing end plate of the caulkinggun in which it will be used. For example, a substantially cylindricalbody with an inner diameter of at least ⅝^(th) inches may be used forwith a standard 10 fluid ounce caulking tube. The body may be perfectlycylindrical or it may taper. The length of the body (the distancebetween the base and the start of the angled portion) is preferablylonger than the length of a standard sealant tube nozzle, which forexample, is generally about 3 inches long on a 10 fluid ounce sealanttube. However, the body may be shorter than the standard length of thestandard sealant tube nozzle over which it is to be placed, so long asthe standard sealant tube nozzle is cut short enough to fit within thebody. For example a substantially cylindrical body with length of 2 and11/16^(th) inches will fit over the straight nozzle of a standard 10fluid ounce caulking tube.

The angled portion can be of any angle, for example deviating between 1degree and 90 degrees from straight (i.e., from the long axis of thesealant tube or the caulking gun barrel). Exemplary angles are 22.5, 30,45, 60, and 90 degrees. U-shaped, hooked, or irregular angles may alsobe employed. Multiple adjoining angled portions may be used to createunique tools. The length of the angled portion can be of any length, forexample, it may be in the range of 1 to 4 inches long.

The wings may be of any size or shape. The function of the wings is toprovide a surface which aids the user in applying rotational pressure tothe body of the nozzle, such that it may be rotated in a circularmanner, which allows the user to position the angled dispensing tip inthe desired orientation. Wings are preferably of adequate size that theycan be engaged by the user's fingers, for example a wing having an areaof about one square inch. Exemplary wing shapes include semi-circularwings, for example as illustrated in FIG. 1. Additional exemplary wingdesigns are illustrated in FIG. 3, including paddle-shaped wings (FIG.3A), rectangular wings (FIG. 3B), polygonal wings (FIG. 3C), circularwings (FIG. 3E). Rod-like protrusions may also be employed. In someembodiments, the wings or protrusions extend one to several inches fromthe outer surface of the body. Longer protrusions provide the user withleverage, and this mechanical advantage can aid in the facile rotationof the nozzle. However, in many embodiments, it is preferred that thewings do not extend substantially beyond the diameter of the caulkinggun barrel, in order to maintain a small profile for use in tight spots.For example, wings extending 0.25 to 1.5 inches from the outer surfaceof the body may be employed.

In many embodiments, the wings comprise a substantially planar“plate-like” body. The plate-like body is generally of a small thicknessrelative to its length and width, for example, having a thickness of 1-5mm. In other embodiments, the protrusions are not flat, but may havevariable thickness, for example in the form of frets, for example asillustrated in FIG. 3D.

A single wing may be used, or multiple wings may be employed. Ifmultiple wings are employed, they may be spaced at any position relativeto each other around the central axis of the body. In general, the useof two wings offset from each other by about 180 degrees isadvantageous, as this configuration allows the user to roll the nozzlelike a knob, with the thumb and forefinger applying laterally opposingforces to the opposite wings, which effects rotation of the nozzle. Thewings may be positioned at any point along the body, so long as they donot impede the fitting of the winged nozzle into the caulking gun. Inthe illustrations depicted herein, the wings are located substantiallyin the center of the body, however they may be located at the base ofthe body or closer to the angled portion of the nozzle, if desired.Likewise, the wings may be located on the body at any location withrespect to the angled portion of the nozzle. In the drawings providedherein, the wings are oriented 90 degrees from the angled portion of thenozzle, however it will be understood by one of skill in the art thatthe wings are not limited to this configuration and may be placed at anypoint around the body with respect to the angled portion of the nozzle.

In most embodiments, the wings protrude radialy from the body of thebody, i.e., they are oriented perpendicularly to the body of the body.However, wings may protrude from the body at any desired angle.

In some embodiments, the wings comprise protrusions adorned with ridges,grooves, knurling, or other features which provide increased grip andwhich aid the user in rotating the nozzle. Alternatively, adhesives ortextured materials can be deposited onto the wings to increase grip. Inan alternative “wingless” embodiment, there are no bodies protrudingsubstantially from the body, and instead the body comprises a region ofridges, grooves, knurling, tacky material, rough material, or adhesives,such region supplying adequate friction to increase the ease of rotatingthe nozzle.

In alternative embodiments, the nozzles of the invention are not usedwith sealant tubes, but are instead configured for use with bulk or“sausage” type caulking guns. Such dispensers typically employsubstantially conical nozzles that are held in place by a threaded endcap that screws onto the barrel of the dispenser. The nozzles of theinvention could be readily adapted for use in such dispensers byemploying a circular base which is of the proper diameter to be heldfirmly in place in a bulk caulking gun. Alternatively, the base of thewinged nozzle, rather than being planar may be conical, such that itfits within a standard straight nozzle used with a bulk sealantdispenser.

Advantageously, the nozzles of the invention may be quickly employedwhen the user encounters a tight spot or difficult application angle,and then removed so that the user can resume using the sealant tube'sstandard straight nozzle. After use, the device will contain un-extrudedsealant material. The device may be disposed of at this point.Alternatively, the excess material may be removed while wet, or,depending on the type of sealant, the sealant may be allowed to cure andthen be readily extracted from the device so that it may be reused.Alternatively, the device may be wrapped in airtight material to preventthe sealant contained within from hardening.

In an alternative embodiment, the invention comprises a sealant tubewith an integral angled nozzle equipped with wings. To rotate the angledtip into the desired position, the user withdraws the plunger or pistonof the caulking gun to releases pressure on the sealant tube, andthereafter the user rotates the entire assembly, including the nozzleand sealant tube body, by engaging the wings and applying rotationalpressure.

The nozzles of the invention may be made of any material which isadequately rigid to channel the flow of the sealant material and whichis adequately resistant to the sealant material such that it will notquickly dissolve or degrage upon contact with the sealant material. Thepreferred composition of the device is polymeric material (“plastic”).Exemplary polymeric materials include polyethylene (e.g., HDPE, MDPE,LDPE, LLDPE), polypropylene (e.g., PP, OPP), blends of PP and PE,polyvinyl chloride (PVC), polyethylene terephthalate (e.g., PET, EPET,PETG, OPET), polystyrene (e.g., PS, HIPS), and polyamide and otherpolymeric materials known in the art. The nozzles of the invention maybe manufactured by any means, including injection molding, compressionmolding, extrusion molding, and blow molding, or machining methods suchas lathing, drilling, engraving, milling, and etching. The nozzles ofthe invention are preferably manufactured as a single piece to reducemanufacturing costs, but may also be manufactured in multiple pieces andsubsequently assembled.

The invention encompasses the various nozzle devices described above,and further encompasses methods of using such devices. Additionally, theinvention encompasses novel ornamental designs for angled caulkingnozzles, for example the winged nozzle design depicted in FIG. 4.

All patents, patent applications, and publications cited in thisspecification are herein incorporated by reference, to the same extentas if each independent patent, patent application, or publication wasspecifically and individually indicated to be incorporated by reference.The disclosed embodiments are presented for purposes of illustration andnot limitation. While the invention has been described with reference tothe described embodiments thereof, it will be appreciated by those ofskill in the art that modifications can be made to the structure andelements of the invention without departing from the spirit and scope ofthe invention as a whole.

1. A nozzle for dispensing sealant material, comprising a hollow tubularbody which is open at the basal end, and which at the opposite endterminates with a hollow and tapered tip, which such tip is angled awayfrom the long axis of the body, wherein the inner lumen of the body iscontinuous with the cavity inside the tip; a plate encircling the outerdiameter of the body's basal end, which such plate extendsperpendicularly from the long axis of the body; and at least oneprotrusion extending from the body, which such protrusion aids ingripping and rotating the nozzle.
 2. The nozzle of claim 1, wherein theat least one protrusion extending from the body of the nozzle comprisesa plate-like structure.
 3. The nozzle of claim 2, wherein the profile ofeach one or more plate-like structures comprises a surface area of atleast one half square inch.
 4. The nozzle of claim 2, wherein the shapeof the one or more plate-like structure is selected from a groupconsisting of the following: semi-circular, circular, polygonal, square,rectangular, or triangular.
 5. The nozzle of claim 2, wherein the atleast one or more protrusions extending from the body comprise twosemi-circular plate-like structures located on opposing sides of thebody.
 6. The nozzle of claim 1 wherein the dimensions of the body andthe basal plate are such that the nozzle will remain in place in acaulking gun when the nozzle is placed over the integral nozzle of astandard sealant tube and when the nozzle and such adjoined sealant tubeare loaded in a caulking gun.
 7. The nozzle of claim 1 wherein theangled portion of the nozzle is angled from the long axis of the body byan angle between 1 and 100 degrees.
 8. The nozzle of claim 7 wherein theangled portion of the nozzle is angled from the long axis of the body byan angle selected from a group consisting of the following: 15 degrees,22.5 degrees, 30 degrees, 45 degrees, 60 degrees, and 90 degrees.